US20190070680A1 - Frame-mounted wire saw cutting systems and methods - Google Patents

Frame-mounted wire saw cutting systems and methods Download PDF

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Publication number
US20190070680A1
US20190070680A1 US16/177,120 US201816177120A US2019070680A1 US 20190070680 A1 US20190070680 A1 US 20190070680A1 US 201816177120 A US201816177120 A US 201816177120A US 2019070680 A1 US2019070680 A1 US 2019070680A1
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United States
Prior art keywords
wire saw
movable pulley
wire
pulley
frame
Prior art date
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Abandoned
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US16/177,120
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English (en)
Inventor
Don Lilly
James Longacre
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gfsi Group LLC
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Gfsi Group LLC
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Filing date
Publication date
Application filed by Gfsi Group LLC filed Critical Gfsi Group LLC
Priority to US16/177,120 priority Critical patent/US20190070680A1/en
Assigned to GFSI GROUP LLC reassignment GFSI GROUP LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LILLY, DON, LONGACRE, James
Publication of US20190070680A1 publication Critical patent/US20190070680A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D57/00—Sawing machines or sawing devices not covered by one of the preceding groups B23D45/00 - B23D55/00
    • B23D57/0007—Sawing machines or sawing devices not covered by one of the preceding groups B23D45/00 - B23D55/00 using saw wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D57/00—Sawing machines or sawing devices not covered by one of the preceding groups B23D45/00 - B23D55/00
    • B23D57/003—Sawing machines or sawing devices working with saw wires, characterised only by constructional features of particular parts
    • B23D57/0038—Sawing machines or sawing devices working with saw wires, characterised only by constructional features of particular parts of frames; of tables
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D57/00—Sawing machines or sawing devices not covered by one of the preceding groups B23D45/00 - B23D55/00
    • B23D57/003—Sawing machines or sawing devices working with saw wires, characterised only by constructional features of particular parts
    • B23D57/0061—Sawing machines or sawing devices working with saw wires, characterised only by constructional features of particular parts of devices for guiding or feeding saw wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D57/00—Sawing machines or sawing devices not covered by one of the preceding groups B23D45/00 - B23D55/00
    • B23D57/003—Sawing machines or sawing devices working with saw wires, characterised only by constructional features of particular parts
    • B23D57/0069—Sawing machines or sawing devices working with saw wires, characterised only by constructional features of particular parts of devices for tensioning saw wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D57/00—Sawing machines or sawing devices not covered by one of the preceding groups B23D45/00 - B23D55/00
    • B23D57/0092—Sawing machines or sawing devices not covered by one of the preceding groups B23D45/00 - B23D55/00 dismountable, collapsible or transportable, e.g. by means of a carrying case
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D57/00—Sawing machines or sawing devices not covered by one of the preceding groups B23D45/00 - B23D55/00
    • B23D57/003—Sawing machines or sawing devices working with saw wires, characterised only by constructional features of particular parts
    • B23D57/0053—Sawing machines or sawing devices working with saw wires, characterised only by constructional features of particular parts of drives for saw wires; of wheel mountings; of wheels

Definitions

  • Wind energy and more specifically the use of wind turbines to generate electricity, is an exploding market.
  • the prospect of recycling wind turbine blades may be attractive and consistent with the notion of wind energy as a “green” power source, it has not previously been technically or economically feasible.
  • experts have regarded wind turbine blades as “unrecyclable” and a problematic source of waste. See Liu et al., “Wind Turbine Blade Waste in 2050,” Waste Management, Vol. 62, pp. 229-240 (April 2017). With the growing importance of wind power in worldwide energy production, this problem will only get worse.
  • the blades can be sectioned into smaller portions at the site of the wind farm.
  • the sectioning can be performed using a variety of methods, such as a wire saw, a circular saw, a grinder, an impact blade, a torch, and a waterjet; however, speed, cost, and environmental concerns limit feasible options for sectioning the blades.
  • a frame-mounted wire saw for cutting an object generally includes a support frame assembly having a first beam having a first lengthwise channel; a second beam having a second lengthwise channel, the second beam positioned in a spaced apart configuration from the first beam; and a third beam positioned perpendicular to and bridging the first beam and the second beam, the third beam coupled to an end of the first beam and an end of the second beam.
  • the frame-mounted wire saw further includes a first stationary pulley positioned near the coupling of the first and third beams and configured to receive and redirect a continuous abrasive wire from a wire saw housing; a second stationary pulley positioned near the coupling of the second and third beams and configured to receive and redirect the abrasive wire from the first stationary pulley; a third movable pulley coupled to a third bracket positioned on the second beam and configured to slide within the second lengthwise channel, the third movable pulley configured to receive and redirect the abrasive wire from the second stationary pulley; and a fourth movable pulley coupled to a fourth bracket positioned on the first beam and configured to slide within the first lengthwise channel along the length of the first beam, the fourth movable pulley configured to receive and redirect the abrasive wire from the third movable pulley, wherein the wire saw housing may be configured to redirect the abrasive wire toward the first stationary pulley.
  • a method of cutting an elongate object with a frame-mounted wire saw generally includes obtaining the elongate object; positioning the elongate object through the support frame assembly; directing a portion of the continuous abrasive wire at an axial speed from the wire saw housing to the first stationary pulley, the second stationary pulley, the third movable pulley, the fourth movable pulley, and back to the wire saw housing; sliding the third movable pulley and the forth movable pulley within the first and second lengthwise channels toward the elongate object; contacting a portion of the continuous abrasive wire between the third movable pulley and the fourth movable pulley to the elongate object; and sliding the third movable pulley and the forth movable pulley within the first and second lengthwise channels such that the continuous abrasive wire travels through the elongate object as the continuous abrasive wire moves
  • the frame-mounted wire saw may further include a fifth movable pulley coupled to the fourth bracket and configured to slide with the fourth movable pulley, the fifth movable pulley configured to receive the abrasive wire from the fourth movable pulley and direct the abrasive wire to the wire saw housing.
  • the support frame assembly may further include a mobility system such that the frame-mounted wire saw is movable along the length of the object.
  • the mobility system may be selected from the group consisting of wheels, continuous tracks, and skids.
  • the frame-mounted wire saw may further include a fluid source for applying fluid to the abrasive wire.
  • the first beam may further include a first upper section adjustable with respect to a first lower section
  • the second beam may further include a second upper section adjustable with respect to a second lower section such that the height of the support frame assembly is adjustable.
  • the adjustment of the height of the support frame assembly may be mechanically assisted.
  • the first and second upper sections and the first and second lower sections may include a plurality of apertures for receiving a removable locking pin therethrough to set the support frame assembly to a fixed height.
  • the object may be a wind turbine blade.
  • the method may further include the step of adjusting the height of the support frame assembly to accommodate various sizes of the elongate object.
  • the step of adjusting the height of the support frame assembly may be performed by adjusting a first upper section of the first beam with respect to a first lower section of the first beam, and adjusting a second upper section of the second beam with respect to a second lower section of the second beam following the step of obtaining the elongate object.
  • adjusting the height of the support frame assembly may be mechanically assisted.
  • the method may further include a fifth movable pulley coupled to the fourth bracket and configured to slide with the fourth movable pulley, wherein the step of directing a portion of the continuous abrasive wire may further includes directing the continuous abrasive wire from the fourth movable pulley to the fifth movable pulley prior to directing the continuous abrasive wire to the wire saw housing.
  • the step of positioning the elongate object may further include moving the frame-mounted wire saw to a position along the length of the elongate object using a mobility system on the frame-mounted wire saw.
  • FIG. 1 is a perspective view of one representative embodiment of a frame-mounted wire saw in accordance with an aspect of the present disclosure
  • FIG. 2 is a flow diagram describing a method for recycling wind turbine blades in accordance with one aspect of the present disclosure.
  • FIG. 3 is a flow diagram describing a method for cutting an object using the frame-mounted wire saw of FIG. 1 .
  • the present application may include references to directions, such as “forward,” “rearward,” “front,” “rear,” “upward,” “downward,” “top,” “bottom,” “right hand,” “left hand,” “lateral,” “medial,” “in,” “out,” “extended,” etc. These references, and other similar references in the present application, are only to assist in helping describe and to understand the particular embodiment and are not intended to limit the present disclosure to these directions or locations.
  • the present application may also reference quantities and numbers. Unless specifically stated, such quantities and numbers are not to be considered restrictive, but exemplary of the possible quantities or numbers associated with the present application. Also in this regard, the present application may use the term “plurality” to reference a quantity or number.
  • Suitable other objects or materials may include scrap material from manufacturing processes (e.g. fiber composite manufacturing processes), or other large objects formed entirely of recyclable materials or a combination of recyclable and non-recyclable materials, such as fiber composite boat hulls and hot tubs, among other objects and materials.
  • manufacturing processes e.g. fiber composite manufacturing processes
  • any suitable object or material may be sectioned using the aspects of the methods disclosed herein.
  • a method for recycling wind turbine blades includes converting a whole wind turbine blade to an output material state that is useful for manufacturing other products, such as those used in construction of buildings, packaging, raw materials, and pellets, among other products.
  • the recycling process is performed while tracking the progress and location of each wind turbine blade such that the direct source of the output material may be determined.
  • the method includes sectioning the wind turbine blades using the embodiments described herein, crushing the wind turbine blade sections, tracking the progress of each blade through the process, and loading output materials into a suitable transportation vessel. Correlating each wind turbine blade to a quantity of output material provides several advantages, including various certifications of the material for uses with restricted or otherwise controlled products and materials, cost savings, and other advantages.
  • wind turbine blades e.g., 100+ feet long and 10+ feet wide
  • cutting a blade into smaller sections is a non-trivial problem to address.
  • the length, width, curvature, and weight of wind turbine blades varies, depending on the size of the wind turbine, anticipated wind speeds, and other design considerations.
  • wind turbine blade sections may extend greater than 40 feet, have an effective width of 9 feet or greater, curve more than 6 feet from blade root to blade tip, and weigh more than 6,500 pounds per sectional piece.
  • a method for recycling a source object such as a wind turbine blade, for providing raw output materials to be used in the production of new composite products, including fiber-reinforced plastics (FRP), is shown.
  • the method generally includes obtaining the source object for recycling, sectioning the source object in to two or more sections using the embodiments disclosed herein, transporting the source object sections to the feed bin of a crushing machine, conveying the source object sections from the feed bin to a rotating crushing drum, crushing the source object sections, the crushing occurring in the rotating crushing drum to produce source object pieces, conveying the source object pieces to a chute configured to direct the source object pieces into a container, loading the source object pieces into the container, and loading the source object pieces into a transportation vessel.
  • a source object such as a wind turbine blade
  • the step of crushing the source object sections is performed with dust suppression measures to limit the environmental impact of the method.
  • a step of weighing the container having the source object pieces is performed prior to loading the source object pieces into a transportation vessel.
  • the step of loading the source object pieces into a transportation vessel generally includes transporting the container to a loading hopper having an auger, unloading the blade pieces from the container into the hopper, and directing the blade pieces through a conduit with the auger to an outlet at the transportation vessel.
  • a source object such as a wind turbine blade
  • the wind turbine blade is sourced at a wind turbine farm where the blade has a specific effective life expectancy. At the end of the useful life, the blade may be selected for removal and replacement.
  • the methods disclosed herein are suitable for recycling the wind turbine blade into raw materials that are useful for creating new products.
  • the wind turbine blade is obtained and partially processed at the wind turbine farm.
  • the wind turbine blade is delivered to a facility for carrying out the steps of the method disclosed herein.
  • any number of blades may be processed simultaneously or in succession. For simplicity, the following description refers to a single wind turbine blade; however, applying the method to any number of wind turbine blades, or other source objects, is within the scope of the present disclosure.
  • the wind turbine blade is sectioned into two or more sections using embodiments disclosed herein, as will be described in greater detail below.
  • the wind turbine blade sections are transported to a feed bin of a crushing machine, block 104 .
  • a crane having jaws, for example, can be used to hoist and load the feed bin, block 104 .
  • the wind turbine blade sections are located in the feed bin for the crushing machine.
  • the wind turbine blade sections are conveyed to a rotating crushing drum of the crushing machine at block 106 .
  • the crushing machine is configured to break the wind turbine blade sections into smaller blade pieces.
  • the step of crushing the wind turbine blade sections may include dust suppression at block 128 for environmental considerations, employee safety, and workplace cleanliness.
  • the method enters block 108 .
  • the blade pieces coming from the crushing machine, block 106 are fed to an inclined conveyor to be transferred to a chute, block 114 .
  • the method enters block 114 , where the chute is positioned at the upper end of the inclined conveyor, block 108 , and configured to direct the blade pieces into a container at block 116 .
  • the method enters block 116 , where the blade pieces are loaded into a container.
  • the method optionally enters block 132 , where the container is weighed.
  • the method enters block 118 , where the container is transported to a loading hopper for loading the blade pieces into a transportation vessel.
  • the loading hopper has an auger for directing the blade pieces through a conduit at block 120 .
  • the method may include a step of grinding the blade pieces to produce blade particles.
  • the wind turbine blade is sectioned into two or more sections using embodiments disclosed herein.
  • the sectioning is performed at the wind turbine farm before the wind turbine blade is transported to a facility to perform the remaining steps of the method.
  • the sectioning step may be performed by any suitable cutting tool, such as a wire saw having an endless loop abrasive cable, a circular saw, a grinder, an impact blade, a torch, or a waterjet.
  • suitable environmental precautions may be taken.
  • an oscillating or reciprocating cable is used.
  • the frame-mounted wire saw 200 generally includes a support frame assembly 260 having a crossbeam 208 , vertical beams 210 supported by base stands 206 .
  • the support frame assembly 260 includes a mobility system.
  • the mobility system includes elongate tracks 202 and wheels 204 , such that the support frame assembly 260 is configured to travel along the elongate tracks 202 .
  • the mobility system is any suitable system to allow the frame-mounted wire saw 200 to travel along the length of an object for cutting.
  • the mobility system includes wheels, continuous tracks, skids, and any other suitable system. In these embodiments, the mobility system may be mechanically assisted, for example, by a motor driving the wheels 204 to move the frame-mounted wire saw 200 along the elongate tracks 202 .
  • the frame-mounted wire saw 200 includes a system of pulleys mounted on the support frame assembly 262 direct an abrasive wire 220 in a desired routing.
  • the abrasive wire 220 is directed through a wire saw housing 250 .
  • the wire saw housing 250 generally includes a power source, a motor, gearing, controls, and other necessary components included in conventional wire saws. These components are not shown in the FIGURES for clarity.
  • a fluid may be applied to the abrasive wire 220 for cooling, dust suppression, cutting quality, and combinations thereof.
  • any suitable pulley system configuration to direct the abrasive wire 220 through the desired routing is also within the scope of the present disclosure.
  • the abrasive wire 220 as the abrasive wire 220 travels away from the wire saw housing 250 , the abrasive wire 220 interfaces a first pulley 230 fixedly mounted to the crossbeam 208 by a stationary bracket 222 .
  • the first pulley 230 is configured to redirect the abrasive wire 220 toward a second pulley 232 fixedly mounted to the crossbeam 208 by the stationary bracket 222 .
  • the first and second pulleys 230 and 232 are mounted to the vertical beams 210 .
  • the first and second pulleys 230 and 232 are mounted to any suitable portion of the support frame assembly 260 .
  • the second pulley 232 is configured to redirect the abrasive wire 220 toward a third pulley 234 slidingly mounted to the vertical beam 210 by a first sliding bracket 224 .
  • the first sliding bracket 224 travels within a lengthwise channel 216 positioned on the vertical beam 210 .
  • the lengthwise channel 216 is configured to allow the first sliding bracket 224 to travel along the length of the vertical beam 210 .
  • the third pulley 234 is configured to redirect the abrasive wire 220 toward a fourth pulley 236 slidingly mounted to the vertical beam 210 by a second sliding bracket 226 configured to travel within the lengthwise channel 216 .
  • the abrasive wire 220 then travels back to the wire saw housing 250 to be redirected through the pulley system.
  • the fourth pulley 236 is configured to redirect the abrasive wire 220 toward a fifth pulley 238 slidingly mounted to the vertical beam 210 by the second sliding bracket 226 .
  • the fifth pulley 238 and the fourth pulley 236 travel within the lengthwise channel 216 as a single unit.
  • the fifth pulley 238 is mounted to an independent bracket that may be stationary or slidable with respect to the vertical beam 210 .
  • the fifth pulley 238 is configured to direct the abrasive wire 220 back to the wire saw housing 250 .
  • the fifth pulley 238 supports the abrasive wire 220 as the abrasive wire 220 travels across the third and fourth pulleys 234 and 236 .
  • fewer than for pulleys or more than five pulleys may be used.
  • the support frame assembly 260 is adjustable in height such that the frame-mounted wire saw 200 is capable of cutting objects in a variety of shapes and sizes.
  • the base stands 206 may include apertures 212 and locking pins 214 which are inserted into the apertures 212 and corresponding apertures in the vertical beams 210 to lock the support frame assembly 260 in position.
  • the adjustment of the support frame assembly 260 is accomplished using a mechanically assisted system, such as a winch, hydraulics, pneumatics, cables, or any other mechanical assist.
  • the object to be cut is a wind turbine blade BL.
  • the frame-mounted wire saw 200 is translated along the length of the wind turbine blade BL by the mobility system including the elongate tracks 202 and wheels 204 .
  • the frame-mounted wire saw 200 is positioned at the desired location for sectioning of the wind turbine blade BL.
  • the wind turbine blade BL is positioned such that the frame-mounted wire saw 200 is aligned with the desired location for sectioning of the wind turbine blade BL.
  • the mobility system of the frame-mounted wire saw 200 may be omitted in favor of a conveyor (not shown) to place the wind turbine blade BL in the desired position.
  • both the wind turbine blade BL and the frame-mounted wire saw 200 are mobile.
  • the abrasive wire 220 is directed through the pulley system of the frame-mounted wire saw 200 .
  • the third and fourth pulleys 234 and 236 are positioned such that the abrasive wire 220 is above the object to be cut.
  • the third and fourth pulleys 234 and 236 are then slid down the lengthwise channel 216 such that the abrasive wire 220 contacts the object and starts to create a cut in the object.
  • the third and fourth pulleys 234 and 236 continue to slide down the lengthwise channel 216 until the abrasive wire 220 cuts through the object creating two sections of the object.
  • the method generally includes obtaining the elongate object at block 300 ; positioning the elongate object through the support frame assembly 260 at block 302 ; directing a portion of the continuous abrasive wire 220 at an axial speed from the wire saw housing 250 to the first stationary pulley 230 , the second stationary pulley 232 , the third movable pulley 234 , the fourth movable pulley 236 , and back to the wire saw housing 250 at block 304 ; sliding the third movable pulley 234 and the forth movable pulley 236 within the lengthwise channels 216 toward the elongate object at block 306 ; contacting a portion of the continuous abrasive wire 220 between the third movable pulley 234 and the fourth movable pulley 236 to the elongate object at 308 ; and sliding the third movable pulley 2
  • the support frame assembly is manufactured from materials and designed in a manner that supports the weight of the wire saw and any other components located on the support frame assembly.
  • the frame is made from 3′′ to 4′′ square tube steel. The size of the frame depends on the size of object to be cut.
  • the wire saw is electrically powered and therefore requires a power source such as a generator (not shown).
  • a cord reel may be included on the wire saw housing 250 .
  • the cord reel allows the stationary power source to power the saw as the power line is pulled out as the saw is operated down the track and recoiled as it is brought back to the start position.
  • the wire saw is gas powered and no cord is needed.
  • the saw is electrically powered and the generator to which the saw is connected is sufficiently small that it is mounted on the wire saw housing 250 and therefore travels with the support frame assembly, thereby obviating the need for a cord reel.
  • the support frame assembly includes a platform sized and configured to support the wire saw.
  • the approximate time to cut blade sections is on the order of 10-25 minutes per sectional piece, a large improvement over the present state of the art.
  • Diamond wire cutting is the process of using abrasive wire of various diameters and lengths, impregnated with diamond dust of various sizes to cut through materials. As a result of the hardness of diamonds, this cutting technique can cut through almost any material that is softer than the diamond abrasive.
  • the embodiments herein may be configured to cut a full wind turbine blade in two pieces in less than five minutes.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Processing Of Stones Or Stones Resemblance Materials (AREA)
  • Wind Motors (AREA)
US16/177,120 2017-03-23 2018-10-31 Frame-mounted wire saw cutting systems and methods Abandoned US20190070680A1 (en)

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Application Number Priority Date Filing Date Title
US16/177,120 US20190070680A1 (en) 2017-03-23 2018-10-31 Frame-mounted wire saw cutting systems and methods

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US201762475779P 2017-03-23 2017-03-23
PCT/US2018/024131 WO2018175957A1 (en) 2017-03-23 2018-03-23 Frame-mounted wire saw cutting systems and methods
US16/177,120 US20190070680A1 (en) 2017-03-23 2018-10-31 Frame-mounted wire saw cutting systems and methods

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PCT/US2018/024131 Continuation WO2018175957A1 (en) 2017-03-23 2018-03-23 Frame-mounted wire saw cutting systems and methods

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US (1) US20190070680A1 (de)
EP (1) EP3448610A4 (de)
CN (2) CN113976999A (de)
WO (1) WO2018175957A1 (de)

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US11225943B2 (en) * 2019-04-23 2022-01-18 Best Blade Recycling, Llc System and method for three dimensional positioning a wind turbine blade and a plurality of saw blades with respect to each other for making a plurality of cuts in a wind turbine blades for recycling
US20220065221A1 (en) * 2020-08-28 2022-03-03 Rzeszów University of Technology Block for geotechnical applications, a method of making a block for geotechnical applications and a method of making a structure using a block for geotechnical applications
US11572646B2 (en) 2020-11-18 2023-02-07 Material Innovations Llc Composite building materials and methods of manufacture

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